Machining distortion minimization for the manufacturing of aeronautical structure

Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal

“…MIRS magnitude is usually much higher than BIRS, and when the inertia of the section decreases below a critical point, as in thin-walled components, their effect can even become the primary contributor for the final machining distortion [11,23,29]. In order to introduce the effect of the MIRS at the surface in the formulation, the bending moments can be calculated similarly through Equations (10) and (11), where the distance from each sublayer to the neutral plane of the cross section is represented by ′ ; the average MIRS in each sublayer is represented by , and is the thickness of each sublayer. MIRS magnitude is usually much higher than BIRS, and when the inertia of the section decreases below a critical point, as in thin-walled components, their effect can even become the primary contributor for the final machining distortion [11,23,29].…”

“…In order to introduce the effect of the MIRS at the surface in the formulation, the bending moments can be calculated similarly through Equations (10) and (11), where the distance from each sublayer to the neutral plane of the cross section is represented by ′ ; the average MIRS in each sublayer is represented by , and is the thickness of each sublayer. MIRS magnitude is usually much higher than BIRS, and when the inertia of the section decreases below a critical point, as in thin-walled components, their effect can even become the primary contributor for the final machining distortion [11,23,29]. In order to introduce the effect of the MIRS at the surface in the formulation, the bending moments can be calculated similarly through Equations (10) and (11), where the distance from each sublayer to the neutral plane of the cross section is represented by k ij ; the average MIRS in each sublayer is represented by σ i sup , and e s is the thickness of each sublayer.…”

“…However, measuring accurately BIRS all along the blank volume is not an easy task. Different techniques were developed to tackle this challenge, namely, the crack compliance method [7,8], neutron diffraction method as Bilkhu et al [9], and also Robinson et al [10] defined the contour method by Zhang [11] and Hill and Olson [12], or layer removal techniques proposed by Treuting in 1951 [13], or Schajer and Prime [14]. Despite being the methods currently employed, most of them are limited to the laboratory environment because of the expensive equipment requirements and the need of specially trained workers to be implemented.…”

Reshaping diagrams for bending straightening of forged aeronautical components

“…Assessing how uncertainties propagate through the different manufacturing steps (i.e. from quenching to machining) is key to keep a high confidence level on the predictions from sequential models [7,21].…”

Molecular dynamics simulations of single grain pure aluminum in a vice fixture for nanomanufacturing applications

“…After obtaining residual stress profiles of the workpiece cross-section, machinists and technicians can create an optimized workflow to help minimize distortion [2]. Machining strategies have been investigated such that the material removal steps are able to minimize part distortion based on geometrical symmetries [6]. Analysis of all the production steps in the manufacturing of mechanical gears has been studied to minimize shape deviations [13].…”